Packaging system for a component including a compressive and shock-absorbent packing insert

ABSTRACT

A packaging system for a component is disclosed. The packaging system includes a compressible and shock-absorbent packing insert, wherein the packing insert includes deformable “cushion elements” that accommodate components of varying sizes and shapes in a protective manner.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to packaging systems and more specifically to a packing insert for use in a packaging system for fragile components.

2. Description of the Related Art

Previous approaches to shipping fragile components (i.e., notebook computers, hard drives, etc.) have typically utilized substances such as resilient foam, as well as adhesives and other non-recyclable materials when packaging such components. Typically in the case of notebook computers, the maximum force that can be applied to all axes in a conventional hard drive is approximately 70 Gs.

FIG. 1 is an exploded view of a typical packaging system 100 for a notebook computer. The system includes a polyurethane bottom cushion 112, a polyurethane middle cushion 114, a polyurethane top cushion 116 and a corrugated tray 118, all of which fit into a corrugated carton 110. Utilizing this approach, the notebook computer to be shipped (not shown) is inserted between the polyurethane top cushion 116 and the polyurethane bottom cushion 112, through the polyurethane middle cushion 114.

The middle cushion 114 defines an opening 120 in which the component to be shipped is placed. The size of the opening will vary, depending upon the dimensions of the component. In the case of original packing (i.e., when the product is shipped from the manufacturer to the consumer), the manufacturer is able to select the size of the polyurethane middle cushion 114 to fit the size of the component being shipped. For example, IBM's ThinkPad® line of notebook computers have similar generic characteristics, but from one model to the next, the overall dimensions, particularly the length and width, can vary by several inches. The manufacturer can have available one size of middle cushion for a first model, a second size of middle cushion for a second model, etc. The manufacturer simply selects the appropriate sized cushion and packs the device into the box.

This requires that the manufacturer keep on hand middle cushions of various sizes. Further, when a consumer wishes to ship a device, e.g., a notebook computer, back to the manufacturer for repair, the standard practice has been to send the consumer a box and shipping materials to be used in shipping the device back for repair. To simplify the process, rather than asking the consumer which specific device is being shipped and confirming the dimensions of the device to be shipped, and then sending a middle cushion that will fit the device, the practice has been to send a “one-size-fits-all” package to the consumer, and then have the consumer conform the packing material to the particular item being shipped. This packaging comprises a middle cushion 114 having a cavity that has “tear outs” that can be removed for different sized products. The larger the product, the more tear-outs have to be removed to accommodate its larger size. Once the tear-outs are removed, they are not replaceable, and the pieces that are removed need to be thrown away.

While providing a convenient solution, the tear-out solution it is not without its drawbacks. For example, once the tear-out inserts are removed, the middle cushion can only be reused with the same sized or larger products. If for some reason a smaller product is substituted for the larger one (e.g., a replacement is shipped to the consumer on receipt of the returned item), a new middle cushion must be used. Second, removed tear-outs typically cannot be recycled in non-industrial environments (such as at the consumer location) and thus must be thrown away, increasing the quantity of non-biodegradable materials in landfills. Further, it relies on the customer to make the right choice on the number of tear-outs to be removed. If too many are taken out, the product will be loose inside the carton, subjecting it to increased risk of damage.

Additionally, the prior art method of using a complete top and bottom cushion, with or without the tear-outs, results in very high G values on “top drops” (the dropping of an object onto the top of the packaging containing an item). This is because, as is known from basic packaging dynamics, the more cushioning material there is in contact with the product, the less the cushioning material can flex, thus increasing the shock force applied to the product. The G value can be lowered by thicker top and bottom cushions, but this increases both packaging and shipping costs.

Accordingly, what is needed is a packaging system and method which provides flexibility in terms of the size of the components being shipped, utilizes environmentally safe and recyclable materials, can accommodate multiple-sized components while still being reusable, and yet safely protects fragile components from potential damage that can be caused during the shipping process. The present invention addresses such needs.

SUMMARY OF THE INVENTION

A packaging system for a component is disclosed. The packaging system includes a compressible and shock-absorbent packing insert, wherein the packing insert includes deformable “cushion arches” that accommodate components of varying sizes and shapes in a protective manner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a conventional packaging system for fragile components;

FIGS. 2-5 illustrate a middle cushion of the prior art tear-away system in varying states of use;

FIG. 6 illustrates a first embodiment of the present invention, wherein “cushion arches” and “cushion nubs” are used instead of tear-outs to enable the accommodation of different sized products, and hold them in place;

FIG. 7 shows the insertion of component 630 into the opening of middle cushion 614;

FIG. 8 illustrates an example of such deformation, in connection with the insertion of component 632 into the same area occupied by component 630 in FIG. 7; and

FIG. 9 illustrates top and bottom cushions used in connection with the middle cushion of FIGS. 6-8, according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

To better understand the present invention, it is helpful to understand the deficiencies of the prior art. The prior art is described below with reference to FIGS. 2-5. FIGS. 2-5 illustrate the middle cushion of the prior art tear-away system described above, in varying states of use. Referring first to FIG. 2, the middle cushion 214 includes a cut-out portion 220 and a plurality of tear-away elements 222A-222N. A single rectangular piece of foam material, e.g., polyethylene foam, polyurethane foam, or polypropylene foam, having a length and width equal to middle cushion 214, is subjected to a first cut that completely removes a portion of the foam equal in size to the cut-out portion 220. To create the tear-away elements, a second cutting process is utilized that makes only a partial cut defining the tear-away elements 222A-222N, i.e., the cut does not go all the way through the thickness of the polyurethane foam, and/or perforating cuts are made along the lengths and widths of the tear-away elements 222A-222N, so that they are not separated from the middle cushion 214, but are easily torn away from the middle cushion as desired. As is well known, perforating cuts can be a series of holes or slits along the length of the tear-away element making it easy to tear the tear-away elements away on a selective basis.

Shown next to the middle cushion 214 are two components 230 and 232 representing two rectangular components of different sizes, each of which are capable of being packed in a package using the middle cushion 214 of FIG. 2. Components 230 and 232 can represent notebook computers, hard drives, and the like. In the example of FIG. 2, both of the components 230 and 232 are larger than the opening 220 and thus neither of them will fit into the middle cushion 214 without the removal of one or more of the tear-away elements 222A-222N.

FIG. 3 illustrates the middle cushion 214 of FIG. 2 with certain of the tear-away elements removed. Specifically, if a person wishes to insert component 230 into middle cushion 214, they can place the component 230 on top of the middle cushion 214 so that the particular tear-away elements that need to be removed to allow the middle cushion 214 to accommodate the component 230 can be estimated. In this example, tear-away elements 222C, F, I, J, K, L, and M have been removed (shown in their removed state below middle cushion 214), thereby expanding the size of opening 220.

FIG. 4 shows component 230 inserted into opening 220. As can be seen, the remaining (those that have not been torn away) tear-away elements 222A, B, D, E, G, H, and N remain in place and provide a limitation on the movement of component 230. It is noted that the removed tear-away elements can no longer be used and are thus discarded.

FIG. 5 illustrates the use of the same middle cushion 214 for use in connection with the shipping of component 232. As shown in FIG. 5, removal of all of the tear-away elements 222A-222N allows component 232 to fit in the opening 220. Once removed, all of the tear-away elements 222A-222N are discarded. Further, the middle cushion is no longer useable to safely ship component 230, since all of the tear-away elements have been removed.

FIG. 6 illustrates a first embodiment of the present invention, wherein compressible and shock-absorbent cushion elements, e.g., “cushion arches” and “cushion nubs,” are used to enable the accommodation of different sized products, and hold them in place. Referring to FIG. 6, a series of arches 634, 636, 638, 640, and 642 are formed as part of frame-shaped middle cushion 614, with the arches extending inward into the inner area formed by opening 620. The arches can be formed using any known method, e.g., cutting or molding polyethylene, polyurethane, polypropylene, or any known cushioning material having resilient properties.

In FIG. 6, Nubs 644 and 646 are formed on one interior side of middle cushion 614, extending into the inner area formed by opening 620 as shown. Nubs 644 and 646 comprise, in this example, semi-circular protrusions formed by cutting and/or molding. The bottom side of opening 620 in this example has neither arches nor nubs extending therein; however, it is understood that any combination of arches and/or nubs can be formed on one, two, three, or all four interior sides extending into opening 620 and still fall within the scope of the present invention. In the preferred embodiment illustrated in FIG. 6, two sides are provided without arches to make it easier to insert a product into the opening 620. The arches and/or nubs exert a compressive force on products placed within the inner area formed by opening 620. Compressing arches on all four sides, or even on three sides, is more difficult than having to compress arches on only two sides as shown. With arches on only two sides, pressure need be exerted against the arches in only one direction (diagonally) to load the product instead of multiple directions. The nubs make the product fit better and allows for some variability in larger products.

Although not limited to such dimensions, applicant currently contemplates two configurations differing only by dimension and selected based on practicality of use and not based on performance characteristics, i.e., the differences in dimensions are based on maximizing the ability to use the packaging material with the widest variety of products, and the dimensional differences do not affect the performance of the packaging materials. In one design, the outside dimensions of the middle cushion are 15″×14.75″, with an opening of 12.625″×10.625″. In another design, the outside dimensions are 16.5″×15.5″, with an opening of 13.625″×11.625″. The arches, in the preferred embodiment, range from 4.5″ wide×1.1″ high (i.e., extension into the opening) to 6″ wide×1.5″ high. Arches of this size give 0.75″ to 1.25″ in dimensional variability (length and width) for products to be used with the packaging. In a preferred embodiment, the material used is extruded polyethylene foam having a thickness of 1.5 inches and a cushion density of 1.7 PCF; it is understood, however, that the present invention is not limited to this material, nor to these dimensional or density characterisics.

FIG. 7 shows the insertion of component 630 into the opening of middle cushion 614. Since component 630 is the smaller of the two components 630 and 632, it deforms the cushion arches and nubs little, if any at all, yet the arches and nubs hold the component 630 in place to limit movement during shipping. In this example the area defined by the arches and cushions in their undeformed state is approximately equal to the are defined by the component 630. However, it is understood that the arches could extend further into the opening 620 that is shown in FIG. 7 and still be able to accommodate component 630, since the arches and nubs are made of deformable material and have room to deform when pressure is exerted thereon.

FIG. 8 illustrates an example of such deformation, in connection with the insertion of component 632 into the same area occupied by component 630 in FIG. 7. Referring to FIG. 8, the cushion arches 634-642 are shown deformed such that they have essentially no curvature and are thus fully compressed against the cushion 614 and component 632. Nubs 644 and 646 are almost obstructed form view, as they too are fully compressed by the component 632. In this arrangement, the component 632 is held in place so that it can move very little, if at all, during shipment. However, in contrast to the prior art, when the component 632 is removed from the middle cushion 614, the arches and nubs reform back to their original shape as shown in FIG. 6. This allows them to be reused with a smaller component, unlike the tear-away system of the prior art.

The arches and nubs provide effective cushioning for the product, against drops and vibration damage. The design accommodates a variety of shapes and sizes, and the configuration can be varied to accommodate almost any size and shape of component. The design also reduces the amount of waste material, since there are no pieces that are removed and discarded by the consumer. Further, there is no judgment required of the consumer, thereby eliminating the possibility that the consumer will render the shipping materials useless for their intended purpose. In addition, the arched shape and the flexed arches (when the size of the component depresses the arches) leads to added protection against damage due to vibration, dropping, etc.

In a preferred embodiment, the middle cushion 614 of the present invention is utilized with a bottom cushion 912 and a top cushion 916, which can then be placed in a box or other shipping container in a well-known manner. As shown in FIG. 9, in accordance with the present invention, the bottom cushion 912 is frame-shaped, defining an inner area (opening) 913, i.e., the center portion of bottom cushion 912 is removed. Similarly, top cushion 916 is frame-shaped, defining an inner area (opening) 917. In addition to reducing the weight of the overall shipping package, the removal of the center portion of the bottom and top cushions 912 and 916 reduces the bearing area (the portions of the cushioning contacting the product) of the top and bottom cushions, which lowers the resultant G's after drops in accordance with well-known packaging dynamics principles. This results in a smaller package with increased protection for the product. The amount of cushioning removed can vary and can be optimized by taking into consideration the size and weight of the product(s) being shipped. In a preferred embodiment the size of the inner areas 913 and 917 is smaller in length and width than the size of the product nested in middle cushion 214. It is understood that only a top cushion or bottom cushion can be used if desired, and that using both top and bottom cushions provides the most protection for the component being shipped.

The arches bend/compress with the larger systems, and thus do not generate additional scrap by the user, therefore reducing the amount of materials discarded into landfills. Any scrap materials associated with the packaging of the present invention will be generated at the supplier site, and can be reused and/or recycled through industrial channels, not available to the typical consumer.

The arches compress and extend for various sized products, so the package can be reused for multiple sized products in multiple shipments. This reduces waste in packaging, as well as reduces the cost of using packaging for each shipment. Also, because the arches compress and extend, they provide additional protection to the product, which results in more protection for less space. This can result in significant size reductions, as much as 33% reductions in some cases. The size, thickness, and number of arches can be adjusted to accommodate larger/smaller, as well as heavier/lighter products.

Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may be suggested to one skilled in the art and it is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims. 

1. A packaging system for components, the packaging system comprising: a first frame, said first frame defining a first inner area in which to nest one or more of said components and having at least one compressible and shock-absorbent cushion element positioned in said first inner area, said cushion element exerting a compressive force on a component nested in said first inner area.
 2. The packaging system of claim 1, wherein said first frame includes a plurality of said cushion elements positioned in said first inner area, said plurality of cushion elements including one or more cushion arches.
 3. The packaging system of claim 1, wherein said first frame includes a plurality of said cushion elements positioned in said inner area, said plurality of cushion elements including one or more cushion nubs.
 4. The packaging system of claim 2, wherein said plurality of cushion elements further includes one or more cushion nubs.
 5. The packaging system of claim 4, wherein said first frame is compressible and shock-absorbent.
 6. The packaging system of claim 5, wherein said first frame and said cushion elements comprise a unitary piece of the same material.
 7. The packaging system of claim 6, wherein: said first inner area has four sides, and wherein said cushion arches are situated along two of said sides, and said cushion nubs are situated along one of said sides.
 8. The packaging system of claim 7, wherein said cushion arches are situated along two abutting sides.
 9. The packaging system of claim 8, further comprising: a box; and a compressible and shock-absorbing bottom cushion; wherein said bottom cushion is placed in said box, said first frame being situated atop said bottom cushion, and said one or more components are nested within said inner area of said first frame.
 10. The packaging system of claim 9, further comprising a compressible and shock-absorbing top cushion, situated atop said first frame.
 11. The packaging system of claim 10, wherein said bottom cushion comprises a second frame defining a second inner area that is smaller than said first inner area.
 12. The packaging system of claim 10, wherein said top cushion comprises a third frame defining a third inner area that is smaller than said first inner area.
 13. A packaging element for components, comprising: a frame, said frame defining an inner area in which to nest one or more of said components and having at least one compressible and shock-absorbent cushion element positioned in said inner area, said cushion element exerting a compressive force on a component nested in said inner area.
 14. The packaging element of claim 13, wherein said frame includes a plurality of said cushion elements positioned in said inner area, said plurality of cushion elements including one or more cushion arches.
 15. The packaging element of claim 13, wherein said frame includes a plurality of said cushion elements positioned in said inner area, said plurality of cushion elements including one or more cushion nubs.
 16. The packaging element of claim 14, wherein said plurality of cushion elements further includes one or more cushion nubs.
 17. The packaging element of claim 16, wherein said frame is compressible and shock-absorbent.
 18. The packaging element of claim 17, wherein said frame and said cushion elements comprise a unitary piece of the same material.
 19. The packaging system of claim 18, wherein: said inner area has four sides, and wherein said cushion arches are situated along two of said sides, and said cushion nubs are situated along one of said sides.
 20. The packaging system of claim 19, wherein said cushion arches are situated along two abutting sides. 